Method and Tray For Mailing Small Objects

ABSTRACT

A method of sending a collection of small objects comprises providing a flexible tray comprising a plurality of compartment indentations each having a depth that is approximately the same, providing a card stock paper, providing an envelope sized to fit the flexible tray, placing at least one small object into one of the compartment indentations, covering the flexible tray with the card stock paper, placing the flexible tray and card stock paper into the envelope, sealing the envelope to form a sealed envelope, and sending the sealed envelope.

REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 61/632,850, filed Jan. 31, 2012, entitled “Battery Mailer Tray.”

BACKGROUND OF THE INVENTION

The present invention relates to a method and thermoformed plastic tray for mailing electronic pet collar batteries or any other small objects.

Mailing electronic pet collar batteries is very expensive when mailed as a package or “parcel” through the U.S. Postal Service.

Other mailers are either too rigid, too thick, or non-uniform in thickness and will not meet the requirements necessary to be classified as a “flat” by the USPS.

As can be seen, there is a need for solutions to these and other problems.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a method of sending a collection of small objects comprises: providing a flexible tray comprising a plurality of compartment indentations each having a depth that is approximately the same; providing a card stock paper; providing an envelope sized to fit the flexible tray; placing at least one small object into one of the compartment indentations; covering the flexible tray with the card stock paper; placing the flexible tray and card stock paper into the envelope; sealing the envelope to form a sealed envelope; and sending the sealed envelope.

In one aspect, the step of covering comprises folding the card stock paper into a top flap and a bottom flap of the card stock paper and placing the flexible tray between the top flap and bottom flap. In one aspect, the top flap and bottom flap each have a dimension approximately equal to a corresponding dimension of the flexible tray so that the flexible tray fits completely between the top flap and bottom flap. In one aspect, the card stock paper and flexible tray mask a shape of the at least one small object, whereby the sealed envelope is approximately flat.

In one aspect, the method further comprises enwrapping the at least one small object in a blister pack before placing it into one of the compartment indentations. In one aspect, the blister pack has a shape approximately corresponding to a shape of the one of the compartment indentations so that the blister pack fits snugly within the one of the compartment indentations.

In one aspect, the card stock paper has a pound weight of at least approximately 50, or at least 65 pounds. In one aspect, at least two of the compartment indentations have different volumes. In one aspect, at least two of the compartment indentations have different cross sectional shapes.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1: is a perspective view of the invention shown in use.

FIG. 2: is an exploded view of the invention.

FIG. 3: is a broken top view of the invention.

FIG. 4: is a broken bottom perspective view of the invention.

FIG. 5: is a side view of the invention.

FIG. 6: is a side view of the invention illustrating flexibility.

FIG. 7: is a section detail view of the invention along line 7-7 in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.

Referring now to the figures, the following reference numbers may refer to elements of the invention:

10: is the thermoformed flexible battery tray.

12: is the battery compartment indentation.

14: is the exemplary envelope.

16: is the exemplary battery in blister pack.

18: is the top flap of card stock.

20: is the bottom flap of card stock.

The battery tray according to the present invention, along with the proper envelope, has been classified by the USPS Pricing and Classification Service Center (PCSC) as a “flat”; other battery mailers will not qualify.

When the present thermoformed plastic tray (battery tray) with batteries inserted is inserted into the proper envelope it allows the finished mailpiece to be classified as a “flat” (or large envelope) instead of a “parcel” by the U.S. Postal Service, thus allowing the user to save on postage. The battery tray along with a cardstock wrap forms a relatively flat-surfaced mailer that is also flexible, in order to meet USPS requirements for a “flat” mailpiece.

This invention is an improvement on what currently exists. No other envelope, box, or packaging system currently qualifies with the USPS as a “flat” when electronic pet collar batteries are inserted into them.

When an electronic pet collar battery (or any other battery or batteries, such as button batteries, or any other small items) is inserted into an envelope, it forms a lump that will not allow the envelope go through the postal equipment that the USPS uses for sorting “flat” mailpieces. Therefore, other mailers do not meet the specifications of the USPS “flat” requirements and are charged a higher “parcel” postage rate.

The Version of the Invention Discussed Here Includes:

-   1. Thermoformed Plastic Battery Tray, according to the present     invention -   2. Paper Wrap, such as a thick paper or cardstock -   3. Envelope

How the Invention Works:

A number of small batteries rest in the cavities of the Battery Tray. The tray is then wrapped with a card stock Paper Wrap. Then the wrapped tray is inserted into an Envelope that creates a mailpiece that conforms to the standards set forth by the USPS Standards for Flats.

How to Make the Invention:

A thin sheet of plastic is heated and then pressed in a two-piece mold, thermoforming a number of attached trays. The sheet of connected trays is then cut by a die into several individual trays.

Envelopes made of different materials (e.g., plastic instead of paper) that are thin and flexible could possibly be used to construct the final mailpiece.

How to Use the Invention:

An Invisible Fence Dealer, for example, would insert 1 to 4 batteries into the cavities of the plastic battery tray, then wrap the tray with the cardstock paper, insert the wrapped tray into the proper size envelope with appropriate addresses, postage, etc., creating a mailpiece that classifies as a “flat.” Invisible Fence Dealers mail a large number of batteries to their retail customers on a monthly basis and by using the present battery tray and appropriate envelope they will save a significant amount of money on postage.

The battery tray can hold a variety of small items and still be classified as a “flat” by the USPS saving money for other companies who mail large numbers of small items.

Referring again to the drawings, a method of sending a collection of small objects comprises:

providing a flexible tray 10 comprising a plurality of compartment indentations 12 each having a depth d that is approximately the same;

providing a card stock paper 18, 20;

providing an envelope 14 sized to fit the flexible tray 10;

placing at least one small object into one of the compartment indentations 12;

covering the flexible tray 10 with the card stock paper 18, 20;

placing the flexible tray 10 and card stock paper 18, 20 into the envelope 14;

sealing the envelope 14 to form a sealed envelope 14; and

sending the sealed envelope 14.

The tray 10 may comprise any flexible material, such as but not limited to plastic, a thin metal (e.g., foil), or composite material. The indentations 12 need not have exactly the same depth d but in a preferred embodiment have approximately equal depths d to allow the resulting sealed envelope 14 have a uniform thickness and, thus, be “flat” for USPS regulations.

The card stock paper may comprise any paper, but preferably a thicker paper, such as a paper having a pound weight (which may be defined by the weight of 500 sheets of 20 by 26 inch paper) of at least 30 pounds, or at least 40 pounds, or at least 50 pounds, or at least 80 pounds. The card stock paper, along with the tray 10, helps to mask the shape of objects inside the tray 10, allowing the resulting sealed envelope 14 to be approximately flat.

The card stock paper 18, 20 may be sized approximately the same as the tray 10 and may simply cover the top of the tray 10, or could, e.g., be approximately double the size of the tray 10 so that the step of covering comprises folding the card stock paper into a top flap 18 and a bottom flap 20 of the card stock paper and placing the flexible tray 10 between the top flap 18 and bottom flap 20. The top flap 18 and bottom flap 20 may each have a dimension (such as a length, width, and/or area) approximately equal to a corresponding dimension (such as a length, width, and/or area) of the flexible tray 10 so that the flexible tray 10 fits completely between the top flap 18 and bottom flap 20. The card stock paper 18, 20 and flexible tray 10 may mask a shape of the at least one small object, whereby the sealed envelope 14 is approximately flat, so that the lumpiness of the small object is not apparent from the outside of the envelope 14.

The method may further comprise enwrapping the at least one small object in a blister pack 16 or other individual wrapping or container before placing it into one of the compartment indentations 12. The blister pack 16 may have a shape approximately corresponding to a shape of the one of the compartment indentations 12 so that the blister pack 16 fits snugly within the one of the compartment indentations 16. In FIG. 7, a blister pack 16 is shown having a shape that fits comfortably within the indentation 12, but not snugly, as there is still a significant gap on either side of the blister pack 16. In another aspect, the method includes adhering (e.g., with an adhesive) and/or connecting the blister pack 16 into the indentation 12, such as with an adhesive tape.

At least two of the compartment indentations 12 may have different volumes, even though they may have substantially equal depths d. At least two of the compartment indentations 12 may have different cross sectional shapes (e.g., circular, rectangular, square, etc.), even though they may have substantially equal depths d.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention. 

What is claimed is:
 1. A method of sending a collection of small objects, comprising: providing a flexible tray comprising a plurality of compartment indentations each having a depth that is approximately the same; providing a card stock paper; providing an envelope sized to fit the flexible tray; placing at least one small object into one of the compartment indentations; covering the flexible tray with the card stock paper; placing the flexible tray and card stock paper into the envelope; sealing the envelope to form a sealed envelope; and sending the sealed envelope.
 2. The method as claimed in claim 1, wherein the step of covering comprises folding the card stock paper into a top flap and a bottom flap of the card stock paper and placing the flexible tray between the top flap and bottom flap.
 3. The method as claimed in claim 2, wherein the top flap and bottom flap each have a dimension approximately equal to a corresponding dimension of the flexible tray so that the flexible tray fits completely between the top flap and bottom flap.
 4. The method as claimed in claim 1, wherein the card stock paper and flexible tray mask a shape of the at least one small object, whereby the sealed envelope is approximately flat.
 5. The method as claimed in claim 1, further comprising enwrapping the at least one small object in a blister pack before placing it into one of the compartment indentations.
 6. The method as claimed in claim 5, wherein the blister pack has a shape approximately corresponding to a shape of the one of the compartment indentations so that the blister pack fits snugly within the one of the compartment indentations.
 7. The method as claimed in claim 1, wherein the card stock paper has a pound weight of at least approximately 50 pounds.
 8. The method as claimed in claim 1, wherein at least two of the compartment indentations have different volumes.
 9. The method as claimed in claim 1, wherein at least two of the compartment indentations have different cross sectional shapes. 